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SIMONA ® PE 100 SPC RC-Line Drinking Water Pressure Pipe 20 Drinking-water pipeline renewed with SIMONA ® SPC RC-Line Protective-Jacket Pipes Project Report
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SIMONA® PE 100 SPC RC-Line Drinking Water Pressure Pipe
20
Drinking-water pipeline renewed with SIMONA® SPC RC-Line Protective-Jacket Pipes
ProjectReport
The project at a glance
Major relining project (long pipe)
Replacement of a drinking-water pipeline section in
an inner city area using minimally invasive long pipe
relining
Requirements
Cost-efficient and ecologically compatible pipeline
renewal in inner city area
Client
Public utility Stadtwerke Mainz Netze GmbH
General Contractor
SAX + KLEE GmbH, Mannheim
MRA Märkische Rohrleitungs- und
Anlagenbau GmbH & Co. KG, Bernau
Planning
UNGER ingenieure Ingenieurgesellschaft mbH,
Darmstadt
Technical Consultant
SIMONA AG, Piping Systems Business Unit, Kirn
Products usedJ SIMONA® SPC RC-Line Protective-Jacket Pipes
(d 450 mm / SDR 17 / 3,700 m) as per
PAS 1075 Type 3
Project duration
4 years
Public utility company Stadtwerke Mainz
replaced a 3.7 km-long section of a major
drinking-water pipeline with a special
emphasis on cost-efficiency and environ-
mental compatibility. The pipeline runs
through the districts of Kostheim and
Kastel and supplies drinking-water from the
Hof Schönau and Petersaue waterworks
to localities east of the Rhine. As it runs
through the inner city area, there was very
little space available for the rehabilitation
project.
2 Project Report 20 04/2014
Location and routing
01_Overview of routing of water main02_ Insertion of SIMONA® SPC RC-Line
Drinking-Water Pressure Pipeline
Public utility Stadtwerke Mainz Netze GmbH operates a
water pipe network spanning some 1,300 km. One sec-
tion of the system runs through the districts of Kostheim
and Kastel. The existing DN 500 pipeline is a mixture of
grey cast iron, ductile cast iron and steel with a retro-
spectively applied internal cement mortar lining.
Because the approximately 70-year-old pipeline was
prone to failure, the company decided to renew it.
01 02
Project objectives
J Economic, durable and permanently tight pipe
systemsJ Ecologically compatible pipe renewal using
drinking-water pressure pipes with special
protective-jacketJ Renewal of the pipeline with minimal disruption
to the public
04/2014 Project Report 20 3
03_Pipes being transported for welding 04_ Welding of SPC RC-Line pipes
in welding container
Cost-effective pipeline replacement using SIMONA®
SPC RC-Line Protective-Jacket Pipes
03 04
A TÜV (German technical inspectorate) report had revealed
beforehand that the entire pipeline no longer met the
specified minimum wall thickness and had to be renewed.
The pipe’s wall thickness was severely reduced in specific
areas due to spongiosis (graphite corrosion).
As part of the system upgrade, the optimum inner dia-
meter of the pipe network was calculated in advance and
it emerged that the pipe cross-section could be reduced.
The pipe is routed through the heavily built-up old town
centres, necessitating a construction method that would
not disrupt traffic or take up a lot of space.
Its positive experience of long pipe relining, even in large
dimensions, led the utility company to opt for the mini-
mally invasive pipe relining method.
With minimal disruption during the construction phase,
a separate, structurally stable new PE pipe was inserted
into the existing pipeline, providing a solution that is
therefore not dependent on the residual service life or
stability of the host pipe.
Long pipe relining is a technically sophisticated process
and requires very accurate preparatory planning. The
internal cement coating of the host pipe, which had been
applied retrospectively in the 80s and 90s, represented
an additional challenge. In the early construction phases
in particular the cement layers had not been applied
uniformly, making the insertion of the new pipe more
difficult.
However, the benefits of a cost-effective, particularly
environmentally friendly and time-saving process com-
pensate for these drawbacks.
4 Project Report 20 04/2014
05_Towing head and centring device 06_Relining in confined urban conditions
05 06
Application
J Predominantly inner-city areas to minimise
disruption to daily life and trafficJ Can be used to replace supply and waste
disposal piping
Background Information: Relining Process
As part of the relining process the existing pipe
is not destroyed, but rather a new pipe is drawn
into it. Using what is known as the annular gap
technique, the new pipe lies on the pipe bot-
tom of the existing pipe after insertion and an
annular gap is created between the old and new
pipe. This method is used whenever the pipe
cross-section can be reduced without causing
any hydraulic impairment of the new pipe. If
requested, or for reasons of structural stability,
the annular gap can be filled with insulating
material.
04/2014 Project Report 20 5
Construction work
In November 2010 work began on the first construction
phase. The work was performed during the months of
September to April, when consumption is lower.
The entire renewal project was completed in 2014 using
SIMONA® SPC RC-Line Pipes d 450 x 26.7 mm, which
provide an effective inner diameter of 396.6 mm fol-
lowing installation.
The decision to employ long pipe relining with SIMONA®
SPC RC-Line Protective-Jacket Pipes to renew a major
water pipeline section through a densely populated
urban area offered significant benefits and will be seen
as pioneering for future pipe replacement projects.
07_ The plastic pipes are highly flexible and can therefore be drawn into narrow trenches
08_Pipe insertion along the B40 federal highway
07 08
6 Project Report 20 04/2014
Consulting and information service
We offer global consulting services, headed by highly
qualified staff at our Technical Service Centre and
within our sales organisation – from project coordina-
tion through product and material selection to on-site
planning.
We provide project planners and customers with techni-
cal and commercial advice regarding choice of products
and material and the most economic pipe-laying meth-
od. We look forward to assisting you with all technical
queries relating to your project, e.g. installation, struc-
tural calculations or joining technology.
Consulting service
Our consultants at the Technical Service Centre look
forward to advising you on the execution of specific
projects:
Phone +49 (0) 67 52 14 - 268, Fax - 741 [email protected]
Delivery service
For further information relating to dimensions and pro-
duct availability, please contact our sales department:
Phone + 49 (0) 67 52 14 - 327, Fax - 710 [email protected]
Training programme
At the SIMONA Sales Academy you can attend product
training courses, familiarise yourself with new processing
methods and practise your skills under the guidance of
our experts – here in Kirn or on your company’s premises.
Find out more at:
Phone +49 (0) 67 52 14 - 251, Fax - 60 251 [email protected]
Information service
We are happy to send you brochures, case studies, video
material and product samples. Please contact our mar-
keting department:
Phone +49 (0) 67 52 14 - 383, Fax - 738 [email protected]
04/2014 Project Report 20 7
SIMONA worldwide
PRODUCTION SITES
Plant ITeichweg 1655606 KirnGermany
Plant IISulzbacher Straße 7755606 KirnGermany
Plant IIIGewerbestraße 1–277975 RingsheimGermany
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SIMONA ENGINEERING PLASTICS (Guangdong) Co. Ltd.No. 368 Jinou RoadHigh & New Technology Industrial Development ZoneJiangmen, GuangdongChina 529000
SIMONA AMERICA INC.64 N. Conahan DriveHazleton, PA 18201USA
SALES OFFICES SIMONA S.A.S. FRANCEZ.I. 1, rue du Plant Loger95335 Domont CedexFrancePhone +33 (0) 1 39 35 4949Fax +33 (0) 1 39 [email protected]
SIMONA UK LIMITEDTelford DriveBrookmead Industrial ParkStafford ST16 3STGreat BritainPhone +44 (0) 1785 22 2444Fax +44 (0) 1785 22 20 [email protected]
SIMONA AG SWITZERLANDIndustriezoneBäumlimattstrasse 164313 MöhlinSwitzerlandPhone +41 (0) 61 8 55 9070Fax +41 (0) 61 8 55 [email protected]
SIMONA S.r.l. ITALIAUNIPERSONALEVia Padana Superiore 19/B20090 Vimodrone (MI)ItalyPhone +39 02 25 08 51Fax +39 02 25 08 [email protected]
SIMONA IBERICA SEMIELABORADOS S.L.Doctor Josep Castells, 26–30Polígono Industrial Fonollar08830 Sant Boi de Llobregat SpainPhone +34 93 635 4103Fax +34 93 630 88 [email protected]
SIMONA AG
Teichweg 1655606 KirnGermanyPhone +49 (0) 67 52 14-0Fax +49 (0) 67 52 [email protected]
SIMONA-PLASTICS CZ, s.r.o.Zdebradská ul. 7025101 Rícany -JazloviceCzech RepublicPhone +420 323 63 78 37Fax +420 323 63 78 [email protected] www.simona-cz.com
SIMONA POLSKA Sp. z o.o.ul. Wrocławska 36Wojkowice k / Wrocławia55-020 ŻórawinaPolandPhone +48 (0) 71 3 52 80 20Fax +48 (0) 71 3 52 81 [email protected]
OOO “SIMONA RUS”Prospekt Andropova, 18, Bl. 6115432 MoscowRussian FederationPhone +7 (499) 683 00 41Fax +7 (499) 683 00 [email protected]
SIMONA FAR EAST LIMITEDRoom 501, 5/FCCT Telecom Building11 Wo Shing StreetFo Tan, Hong KongChinaPhone +852 29 47 01 93Fax +852 29 47 01 [email protected]
SIMONA ENGINEERING PLASTICS TRADING (Shanghai) Co. Ltd.Room C, 19/F, Block AJia Fa Mansion129 Da Tian Road, Jing An DistrictShanghaiChina 200041Phone +86 21 6267 0881Fax +86 21 6267 [email protected]
SIMONA AMERICA INC.64 N. Conahan DriveHazleton, PA 18201USAPhone +1 866 501 2992Fax +1 800 522 [email protected]
Upon publication of a new edition all previous editions shall become void. The authoritative version of this publication can be found on our website at www.simona.de. All information furnished in this publication reflects our current scope of knowledge on the date of publication and is designed to provide details of our products and potential fields of application (errors and omissions excepted, including typographical mistakes).
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